Electric control circuits



Maya, 1944 J. A Km: 2,348,259

ELECTRIC CONTROL CIRCUIT Fild May 14, 1942 INVENT OR JOHN A. KRATZ BY" I v ATTORNEY Patented May 9, 1944 ELECTRIC CONTROL Ema HITS John A. Knits, Yonkcrs, N. Y", asslmnor to The Linda Air Ohio iroducts Company, a corporation of Application May 14, 194 2, Scrlal No. aces-o2 lot. arc-co This invention relates to electric control cir cuits, and more particularly to a control circuit ,cmbodylng two or more control devices in which a control voltagels applied to one device and this device applies the control voltage to the other device or devices.

In many control installations, space discharge devices, usually of tho "thyratron type, are usedto control the energirotion or? on electrically op-= erated elcment in rcsponse to certain predctcr mined electrical characteristics. l rsoucntly, two or more oi those grid-controlled space discharge devices are used in order that lull wove rectified current may be supplied to the elcctrlccl element. Due to differences in tho clicractcristics oi. the space discharge devices or dldforcnccs in ombient temperatures, when two or more oi the devices are controlled by the some voitogc, they vcry often do notsbecome conductive substantially the some value of control grid volt-ago, rcsulting in a fluctuating output voltage, In some control applications, it is essential that the devices re spond substantially uniformly to very minute changes in the control voltage.

Such control circuits have been adapted slor use in automatic electrlc' welding, wherein the spacing between the end of the welding rod and the work-has been maintained substantially uniiorm by controlling the operation of an electrode feeding means or mechanism in accordance with electrical conditions existing in the welding zone Generally, the welding voltage, or a suitable frac tion thereof, is impressed upon the grids or a pair of space discharge devices which are used to supply lull wave rectified current to the electrode feeding mechanism, The characteristics of the discharge devices are so selectedthat, when the welding voltage exceeds a predetermined value, which it does when the spacing between the end of the electrode and the work 40 lulu; increased beyond a predetermined amount. the voltage applied to the grids will exceed a critical value and the space discharge devices become eflective to permit current to pass to the feeding mechanism. The latter thereby operates to advance the electrode toward 'tt'ie'work until the predetermined electrode-work spdclng is reline of weld. If the control declces do not becor-no conductive at sulcctcntlw tlac some value of control {grid voltage, the prccislon o! control is adversely cficcted. Specifically, it one device becomes conductive ct o grid voltooc of 30 volts and the other ct c voltocc of co volts, for

' instance, and the control voltage impressed on the izrlds is 395 volm, only one dov-lcc will ice opcratlto to pcsc current. Hence, only half wave rectified curront will loo mlilillflbk for the electrode feeding mecircnism or other controlled device.

it is thoroiore among the oirlccts of this incaution to provide o, control system including two or more control-devices in which o. control voltage impressed on one dcvlcc and "the other devices ore controlled by the first devlcc; to provide on improved electric wclolinc circuit including o. pair of grid contromcd some dischcro'e devices eficctlvc to energize an electrode leading motor in 'wl'dch o suitable proportion of the welding voltage is impressed on the grid of one oi the devices cod :9. control voltagc is impressed on the grid welding control circuit embodying 8, pair of grid controlled space discharge devices in which the respective devices will become conductive not more than ,4; cycle before or after each other;

' and to provide an improved, eflective, and sensitlve control system particularly adapted for controlling automatic electric welding operations These and other objects of the invention will in part be obvious and in part become apparent from the following description and the accompanylng drawing, in which the single figure diagrammatically illustrates an electric welding sysattained. At such time, the grid voltage drops below the critical value and the feeding mech anlsm is no longer supplied with current.

Precision or control is desirable in such weldin; operations in order to produce strong welds of uniform quality, to control the amount and character ,of the fusion of the weld metal and tern embodying the principles of the invention. In its broadest aspects, the invention relates to anelectrlcal control system embodying a plu-' rality of control devices, the energization of one of which devices is controlled in response to an electrical characteristic 0! the controlled circuit and this device in turn controls the energization of the other devices. More particularly, the invention relates to a motor energization control circuit embodying control devices, and in which the activation 01' one device is controlled in remuse to an electrical characteristic which is a the'work. ind to heat-thewo'rk evenly adon: the 56 function of the operation of the motor. and this electrical device, it will, for purposes of illustration, be described more particularly as applied to an electric welding control system. However, it is to be understood that the invention is not The output circuit of this space discharge device is then so related to the grid or control circuit oi the other space discharge device that, when limited to electric welding but is capable of ap- I plication in any y of control system embodying a plurality of control devices,

Generally speaking, in accordance with the "principles of the present invention, power for energizing an electrically operative device, such as the electrode feeding mechanism in an automatic electric welding system, is supplied through a plurality of grid-controlled space discharge devices of the type which permit a flow of current w en the relative positive potential oi the control grid with respect to the cathode exceeds a certain' value, hereinafter called the critical value.

theiirst space discharge device becomes conductive, a potential above the critical will be impressed, during the next /5 cycle or the voltage wave, upon the grid of the second space discharge device which thereupon becomes conductive not more than ,5 cycle before or after the. 10 first space The two space discharge devices thus act in uni-.

discharge device becomes conductive.

sonto provide full wave rectified current for the electrically operative device, or in the case of welding, for the electrode feeding mechanism. It will thus be seen that one space discharge device is operative in response to energiz tion of the other spacedischa'rge device, whereby it is assured that both space discharge devices will operate to supply full wave rectified current to a the feeding in when the welding, voltage When such relatively positive potential oi the control grid is less than this critical value, the power supply to the feeding mechanism is interrupted.

Through a suitable control circuit, a voltage is impressed upon the grid or control circuit of one of the space discharge devices, which voltage is proportional to a characteristic 0! the welding circuit. In the usual case, such voltage may be 0 directly proportional to the welding voltage or cm'rent, and is impressed across the grid and cathode of one 01' the space discharge devices. Means may be provided so that. if the voltage exceeds a predetermined value, the voltage impressed on the grid of the space discharge device will exceed the critical value. Hence, in a welding circuit, when the distance between the fusible end of the electrode and the work increases, thus increasing the welding voltage drop, the space discharge devices supp y current to the feeding mechanism. The feeding mechanism thereby becomes operative to advance the elecexceeds a predetermined value.

In'the drawing, the principles of the invention have been illustrated as applied to the automatic electric welding system described and claimed in U. 8. Patent No. 2,260,510, issued October 2'8, 1941, in the name of Edwin A. Clapp. In order to sim- Dliiy the drawing however, the means described and claimed in the patent for rectifying an alternating current welding voltage andimpressing the resultant unidirectional potential upon the grid of the space discharge devices hasibecn omitted irom the drawing, although the connections ior associating this feature of the Clapp system with the system 0! the present invention have been illustrated.

The welding circuit includes an'electrode E2.

work W, and conductors II and I2 connected re spectively to the electrode E and the work W. The other ends of conductors II and I! may be connected, through a suitable switch, toasource of either direct or alternating electric current, both oi! which, for the sake oi simplification, have been omitted from the drawing. A current limiting impedance ll, which maybe a resistanceii the welding current is direct current or an inductive reactance i! the welding current is alternating current, may be included in the conductor ll.

The electrode ieeding mechanism comprises a motor M driving rollers'R' which engage electrode so Ito vary itsposition relative to work W. Electlm the critical value and the power supplyi'or i'eeding mechanism is accordingly inte mpte The space discharge devices maybe conas an electric valvearrangsment control- ,apu nmtobe tzicalenergyior theelectrodeieedingmechanism and its associated controlsystemissuppliedh'om a suitable source 0! alternating current energy, not shown, through conductors 1. and II can-- nectedtothenxedterminalsllandflotanautotransformer 34. A conductor 2| connects terminsilltooneendoitbeprimarywindinglloi' atranstormertlmndaoonductorltconnectsthe otherendotprimarywindingtltoanadiustabie up a on autotransiormer u. a pair r con-.

ductors ilandfl connecttbeprimarywinding 88 of a transformer II to conductors]. and ll. respectively, Transformer is provided witha plurality oisecondsrywindinssn, u, and u, for

A constantunidirectional potentialisi'mpressedontheshuntiieldwindingl'oi orai'uilwave iorlncs'llandtbe nsatadbv' mimisolthe msmentorcathodeiliseon- I0 and fltoopmsite terwindhmllostbeinnssecondary sou-met 40. The mid-point 8 meme,

dsvieell. 'Thcanodesllddcmll byconductorlllandlltoow te 'te'rminalsolthese'emdarywindmgllortransing N and the mid-point 66 or secondary winding to are connected by conductors i8 and It, re

spectively, to opposite terminals of the field winding F.

The armature A of the motor M is energized with unidirectional current through the medium oi a pair of grid-controlled space discharge'de vices I2 and I4. Each of these devices comprises nected'to the cathodes dd oi the space discharge an anode IS, a control grid I8, and a cathode 1B0 indirectly heated by a filament 82 which is supplied with current through conductors at and 86 connected to opposite terminals of the secondary winding 42 ct transformer 50. The discharge devices I2 and 14 are of the thyratron tube type, such as the FG -33, which er mit the flow of current when the relative post tive potential of the grid with respect to the cathode exceeds a certain critical value. When this relative positive potential of the grid is less than the critical value, the devices interrupt the ilow of current through the circuit which they control. The grid-anode characteristic of these tubes is approximately vertical so that the guid ignition potential is practically constant for all anode voltages within the voltage range of the tube. This characteristic increases the sensitivity of response and simplifies the circuit design.

The terminals 88 and 9|! of secondary winding 9! of transformer 30 are each connected by an input circuit including conductors 82 and 94, respectively, to the anode T6 of one oi the space discharge devices 'i2 and I4; A conductor 9t connects the mid-point 58 of the secondary winding St to an input terminal of a reversing switch S, and a conductor I connects the other input terminal of the reversing switch s to cathodes 80 of the devices I2 and I4. Conductors I02 and I04, connect the output terminals of reversing switch S to opposite sides of the armature A of the motor M. The reversing switch S may be used to adjust the position of the tusing end of the electrode E with respect to the work W preliminary to beginning a welding operation, and may also be used to retract electrode E from the work W when the welding op eration has been completed.

The control circuit includes a pair of conductors I06 and I08 connected at one end to the conductors III and I2, respectively, of the welding circuit, and at the other end to the center pair of terminals of a double-pole, double-throw switch H19. Switch I09 constitutes manually operable means for selectively conditioning the control system for operation with either direct current or alternating current applied to the weld ng circuit, as fully described and shown in the-Clapp patent mentioned above. Through the medium of switch I", a unidirectional potential is impressed on the control circuit of device 12 irrespective of whether the welding circuit is supplied with direct current or with alternating current. When the welding current is direct current, switch III! is closed to the left, as viewed in the drawing, to connect conductors IIIG and III to a pair of terminals IIII. When the welding current is alternating current switch I09 is thrown to the right, connecting conductors Mi devices it and id, drelativelv positive zuiiustable tap M2 ol' thepotentionieter is connected by a conductor iii, through a voltage limiting resistance tit, to the arid lit oi the space dis charge device id; lily suitable adjustment of the tap B22, a potential proportionate to the volt age drop across the welding zone maybe if pressed across the grid l8 and cathode do of the space dis'charse device "it when the welding cir suit is enenj in accordance with the principles oi the present invention, a proportionate part oi the Welding voltage is impressed on the grid "ill oi. the space discharge device it only, and not on the grid of the space discharge: device it. The no of the device id in the following manner.

tential-applied to the grid 1 8 of the space discharce device it is derived iroin the output circuit oi the space discharge device '82, in a manher to be descriiced. I

The controi potential is applied to the grid it The output potential of the space discharge device It is impressed on the low impedance primary winding lid of a current transformer M2, which primary winding is connected in series with cathode as oil device it. Since the current in this windingvaries from zero to a maximum to zero during each halt cycle, an alternating current.

voltage will he generated across the high voltage secondary winding iii of the transformer 632. This voltage is applied, through resistance E35, to the grid it of the space discharge device It.

A condenser E39 is connected in parallel with the secondary winding tilt so that the positive phase of the potential generated by the transformer I32 will be maintained on the-grid E8 of the space discharge device id until the start of the positive half cycle across the anode l6 and oath-- ode 80 of the device i4. When the space discharge device 52 is conductive, the voltage impressed on the grid "it of the space discharge device II through the current transformer in is above the critical voltage and therefore the do vice M will become conductive.

" The circuit for impressing the output voltage of the space discharge device "l2 on the primary f winding for the current transformer I32 is as follows: Cathode "'of'device I2, conductor I, winding I39, conductor m, conductor I00, switch 8, conductor I, armature A of motor M.

conductor I02, switch S, conductor 85, mid-point ts to terminal a through winding 9| or transiormer 30, conductor '2, and anode ii of de- Be'ctified unidirectionallcurrent is supplied to the circuit of motor armature A as follows: Through the conductors I6 and .Ill, an alternatin potential is impressed on autotransformer 20,

and I08 to a pair of terminals H2. As described in the above Clapp patent,the terminals H2 are circuit so that a unidirectional potential will be impressed on the control circuit. As such circult forms no part 0! the present invention, it

and through adjustment ofv tap 33, a preselected proportion of this potential is impressed on the primary winding 2; of transformer 80.v During that portion of the alternating current cycle in which, by virtue oi'conditions existing in the sup ply .circuit, the terminal 88 of the secondary winding 9| 0! transformer 30 is positive with respect to the mid-point- 98 and with respect'to terminal 85, voltage will be applied iro'm terminal through conductor 92 to anode 16 of the device 12. If, at this time, the relative positive potential 01' control grid II is such that it will permit the device 12 to becomeactive, current will flow from the anode II to the cathode 80 and through an output circuit including conductor I, winding Ill and conductors I42, I00, and I04 to one armature terminal of the motdr M. From the opposite armature terminal oi. the motor M, the current will flow through the remainder of the output circuit including conductors Hi2 and 96 to the mid-point 08 of the secondary winding 9i, and through the winding 9| to the terminal 88. At the same time, as the terminal 90 is negative with respect to the terminal 88. and the mid-point 98, no potential will be applied to the device 14.

At the same time however. a varying potential is applied to the winding IIII oi the current transformer in, generating a high potential on the secondary winding ill of this transformer. The current due to the generation of this potential is stored in the condenser I38. During the next half 01' the cycle, terminal 90 will be relatively positive with respect to mid-point 88 and terminal III of the secondary winding 8| oi the transformer 38. During this half cycle voltage will be applied from terminal 90 through conductor 94 to the anode ll oi the device H. At the same time, the condenser ill will discharge, applying a potential above the critical to the grid ll of the device 1|, whereby current will flow through the device 14 from the anode I! to the cathode 80,

and thence through an output circuit including the conductors ill and I to one side of the armature A oi the motor M. From the other side of the armature A the current will flow through the remainder of the output circuit including conductors I02 and" 88 to the mid-point 98 of the secondary winding of the transformer 30 and through this secondary winding back to the terminal 00. It will thus be observed that full wave rectified current is supplied to the motor armature A. At the same time, the circuit including field winding Fis supplied with current from the full wave rectifying device I, the operation of which will be readily understood upon inspection.

As the potential applied to the grid I8 01' the device 14 is derived from the output circuit of the space discharge device 12, the device 14 will become conductive not more than cycle later than the device 12, irrespective oi. variations in the constants of the device I4 with respect to those of the device 12, or variations in the respective ambient temperatures of the two devices. Therefore. extremely sensitive control of the energization oi the motor armature A is obtained,

' as itis assured that the devices I2 and 14 will become conductive not more than cycle before or after each other. It will be noted that the conductivity of the space discharge device I2 is controlled by the voltage impressed on the potentiometer HI, and device 12 in turn controls the ducflvjty r the device 14 so that there is no possibility that either of the devices will become conductive more than ,5 cycle before or after the other one.

'Ihe operation of the welding system will now be described in detail. Before beginning the welding operation, motor M is energized to advance electrode E into operative relation with the work W, "and with the fusing end of the electrode positioned atthe preselected distance from the work W. Tap II oi autotransiormer 24 is then so adjusted that, when the motor is energized,

it will operate rapidly enough to advance the electrode toward the work at a rate slightly in excess of the rate of consumption of the electrode.

If the current flowing in the welding circuit is direct current, switch IDS is closed to the left, whereby the welding potential is impressed directly on potentiometer H8 through conductors HIS and )8, switch I09 and terminal iiii. If alternating current is flowing in the welding ciccuit, switch I09 is closed to the right, whereby a unidirectional potential is impressed on potentiometer H8 through the circuit described and shown in the above mentioned Clapp patent. In either event, the connections are 50 arranged that the fixed terminal H4 oi! the potentiometer is relatively positive and fixed terminal H6 relatively negative.

The adjustable tap I22 of the potentiometer H8 is then adjusted so that, when the spacing between the electrode E and the work W exceeds by a slight amount the desired spacing, a sufficient portion of the welding voltage will be impressed between the tap I22 and the terminal H6 that the relative positive potential of the grid 18 of the space discharge device I2 with respect to the cathode 80 thereof will exceed the critical value. Under such conditions, the device 12 will become conductive permitting current to iiow in the motor armature winding circuit and will in turn apply a potential above the critical to the grid 18 of the device 14. The motor M will then move the electrode E toward the work W until such time as the predetermined spacing between the electrode and the work has been re-established. When this occurs, the welding voltage will have dropped to a value wherein the potential existing between tap I22 and terminal H6 will be less than the critical relative positive potential of the grid 18 of device 12 with respect to the cathode 80 thereof, thereby interrupting the flow of current through the motor circuit.

When the device 12 is conductive, a potential is impressed from the output circuit of the device upon the winding In of the transformer H2, and as this potential is varying in value, a high alternating current potential is generated in the winding I" of transformer I32. The current due to this potential is stored in the capacitance or condenser I38 until such time as the terminal 01 transformer 30 is relatively positive with respect to mid-point 98 and terminal 88 thereof, whereupon this potential will be impreued on the grid 18 of device 14 so that current will be supplied to the motor armature A during the succeeding halt cycle.

From the foregoing, it will be apparent that an improved and simplified electrical control system has been provided in which the sensitivity of control has been increased by insuring that the space discharge devices will become conductive not more than ,5 cycle before or after each other. It will be apparent that this is accomplished by impressing the control potential upon the control or grid circuit of only one of the space discharge devices and impressing a potential upon the control or grid circuit of the other space discharge device from the output circuit of theflrst discharge device. The control system is eflective in many applications, particularly in applications'in which the speed oi an electrical mechanism, such as a motor, is to be regulated in accordance with predetermined conditions. More broadly, the control system is applicable to control output circuits of a pair of space discharge devices in accordance with predetermined velues of an electrical charncteristic of a controlled circuit, the value of which characteristic is oontrolle'dby electrically operable means supplied with current irom said output circuits. The control system is particularly applicable to automatic electric weldin operations wherein the end o fusible electrode in to be maintained in predetermined relation to the work to be welded. In ouch latter epplicetlonc, g charactcrlctlc of the welding zone, such we the voltage or current, is used to control the potential applied to the grid of the ilrct space discharge device, which device, in turn, controls the potential applied to the grid of the second space discharge device, thereby g that both devices will become conductive not more than cycle before or often one another.

While a. specific embodiment of the invention has been illustrated, lt ie to be understood that thin embodiment is exemplary only, end that the invention may be otherwise embodied.

"What is claimed is: l. A motor speed-control system comprising,

electrode toward. the worlc; u pair of grid-con trolled space horgo devices controlling the energizotion of cold electrically operoblo leedmg means; meenc rcoponoive to on electrical con-- lid in combination, o motor having at field circuit end on armature circuit; means for applying a. substantially constant uni-directional potential to said field circuit; a pair of space dicchorge devices each having a control circuit and on output circuit, each control circuit including a control grid and a cathode, and each output circuit including an anode, said cathode, and said armoture circuit; means, responsive to the operation of said motor, for applying a. variable control voltage to the control circuit of one device; and

means, connected to the output circuit-oi said one device, for applying -a,'potential to the control circuit of the other device.

2. The combination claimed in. claim 1, in which said means tor applying a variabie'control voltage to the control circuit of said one device comprises an adjustable impedance; means connecting the cathode of said one device to a, point of relatively negative potential on sold adjustable impedance; and means connecting the grid of said one device to an adjustable point of relatively positive potential on said impedance? 3. The combination claimed in claim 1, in which the means connecting the control circuit of said other device to the output circuit oi! said one device comprises a. transformer having a primary winding connected in series with the output circuit or said one device and a secondary winding connected in the control circuit 01 said other device; and a capacitance connected in parallel with said secondary winding.

4. An electric welding system comprising, in combination, a welding circuit including a. fusible electrode and the work to be welded; electrically operable feeding means tor advancing said elecm trode toward the work; a, pair of grid-controlled space discharge devices controlling the energizetion of said electrically operable feeding means; means responsive to an electrical condition of said welding circuit Iorinitially rendering only one of said devices-operative to energize said elecu'lcally operable feeding means; and means responsive exclusively to the operative condition or said one device for rendering the other device operative to energize said electrically operable 7 feeding means.

5. An electric welding.system comprising, in combination, a welding circuit including a fusible electrode and the work to bewelded; electridltion of said welding circuit for ccntrog the energizotion .of only one or sold devices; and mcanc respective exclusively to on electrical condition of the output circuit of cold one device lor applying an cnerglcing potential to the other olevice; whereby, upon energlzotlon oi cold one device, both devices will he operative conlolntly to supply lull wove rectified current to sold elec tric operelole ieedlng moons..-

d. All electrlc welding eyctem comprising, in combination, to welding circuit including o, luolble electrode and the worn to be wcldcmclectrlcclly operable lecdinc mount tor odvonoing cold eleo trodc towurd the work; e um cl grid-controlled space devices controlling the coercive-- tion of cold elcctrlcnllv operolole feeding menus; on odjuctoble potentiometer connected in por ellel with cold welding circuit; moons connecting said potentlometer to the grid circuit ol only one.

of cold devices; end means connecting the output circuit of cold one device to the grid clr= cult oi the other device; the output circuits of both of cold dovlcce being connected to cold electricolly operable lee meone whereby, when a potential above the critical ic opplied to the grid circuit oi one device, both devices will he come operative conlointly uupply full wove rectified current to said electrlcolly operohle' feeding mount,

"1, An electric welding cystemcomprlsing, in 1 mg circuit; and mono operatively associating the output circuit oi cold one device with the grid circuit oi. cold eecongl device; whereby, when a poten above the critical is applied to the grid circuit oi cold one device, both of cold devices will become operative coniointly to supply lull wave rectified current to said electrically operable feeding means. 8. An electric welding system comprising, in combination, a. welding circuit including a. fusible electrode and the work to be welded; on electric motor including an armature winding and o shunt field winding tor advancing said electrode toward the work; as pair of grid-controlled space discharge devices connected in series with the armature winding oi said motor; means for applying a unidirectional potential to the field winding of said motor; means for applying a. proportionate part of the welding voltage to the grid circuit of only one of said devices; and means connecting the output circuit oi said one device with the grid circuit of the other device; whereby.

combination, a welding circuit including a. fusible Y .cally operable feeding means for advancing said 7 electrode and the work to be welded; electrically operable feeding means for advancing said welding electrode toward the work; a pair of gridcontrolled space discharge devices controlling the energization of said electrically operable means; means connected in parallel with the welding circuit for applying a potential to the grid-of only one o! said devices; means, including a tranc former connected to the output circuit of said one deviw for applying a potential to the grid of the other device: and a capacitance connected in parallel with the secondary winding of said transformer; whereby, when a potential above the critical is applied to the grid of said one device, both of said devices will become operative conlointl'y to supply full wave rectified current to said electrically operable means.

10. An electric welding system comprising, in combination, a welding circuit including a fusible electrode and the work to be welded; electrically operable feeding means for advancing said electrade-toward the work; a pair of grid-controlled space discharge devices, each having an output circuit connected to supply current to said elecondary winding of said transformer; whereby,

when a potential above the critical is applied to the control circuit of said one device, both of said devices will become operative conlointly to supply full wave rectified current to said electrically operable feeding means.

JOHN A. KRATZ. 

